Conductivity testing apparatus



Feb. 25, 1941. G, A, MATTHEWS 2,232,715

CONDUCTIVITYlTESTING APPARATUS Filed Feb. 14, 1940 f 21 sheets-sheet v1` F23. I Y

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y Feb. 2.5, 1941.v G. A. MATTHEWS I QONDUCTIVITY TESTING `APPARATUS Filed Feb. 14, 1940- 2 Sheets-Sheet 2 Peteerea Feb.2s,11941 PATENT orlucl-zv coNnUcTrvxTr TESTING ArrAnATUs George A. Matthews, Detroit-Mien. Appueeubn February 14, 1940, serial No. 318,925

' s claims. w1. ris-18a) This invention relates to apparatus for testing electrical equipment and more particularly to apparatus for testing and measin'ing, by a comparison method, the conductivity of normally low resistance circuit connections and joints -in Vsuch electrical equipment as circuit breakers, switches, bus bars and the like that carry heavy currents. K

Reliable operation of various types of Aequipment in a power distribution system can be insured only by periodic inspections or tests and, 'to

reduce the time during which the equipment is withdrawn from service, such inspections or tests should be made in the eld and should be completed as rapidly as is possible. The practice has been to judge thecondition of bolted connections at bushing joints and bus connections, and oi.' the contacts of circuit breakers and switches by a visual inspection, by the measurement of millivolt drop across joints or contacts, and by the measurement of resistance by the Wheatstone bridge or low resistance reading ohmmet'er. The judging or measurement of contact resistance by these methods has proved unsatisfactory for a number of reasons. The milli-volt drop method is unsatisfactory since a poor joint or contact may pass all oi the test current through the millivoltmeter, thusl destroying the instrument. Both the Wheatstone bridge and low resistance reading ohmmeter may. indicatea low resistance when the joint or contact is subjected to a low value test current but, when the joint is subjected to load current, high resistance may develop due to the failure of the joint or contact load. v A

The visual inspection method is not applicable to some types of connections and involves conto sustain rated siderable expense in the case oi taped joints and circuit breaker contacts. The inspection of the contacts of oil circuit breakers has been particularly expensive in view of the time and the number oi men required to drop the tanks or to drain the oil and open manholes. The cost of. a visual inspection of the contacts of a three-phase, 132

kilovolt outdoor circuit breaker is oi' the order oi $120.00, and of a 24 kilovolt circuit breaker about $38.00. Regardless of expense, the'visual inspec-l tion method is open to the objection that the equipment is out of service for an extended period and, even in an emergency, cannot be returned yto service in less than several hours.

An objectfof the present invention is to provide apparatus of simple construction that can be used in the iield by unskilled workmen, and which is not subject to damage from overloads, for testing the conductivity of normally low resistancev connections in electrical equipment. An object is to provide apparatus for testing the conductivity of circuit connections by subjecting them to current ow of the orderof that normally carried by the circuit connections. An object is to provide portable testing apparatus for supplying a heavy direct current to the connection under test and to a low resistance shunt-across that connection, and ammeters for measuring the total current ow and the current through the low resistance shunt. A further object is to provide testing apparatus of the type lastL stated that includes rectiers for developing a direct current of the order of upward former and rectifier i'or developing a direct cur-v rent from an alternating current source;

Fig. 3 is a curve sheet showing curves indicating the maximum allowable current through the shunt resistance for dierent types of circuit `breakers at diiferent total currents through the testing apparatus:

Fig. 4 is a curve sheet showing the relation be tween the resistance of the test specimen and the current through the shunt resistance for a given value of the shunt resistance and a given total current'ilow;

Fig. 5 is a side elevation, with part of the casing broken away, of the testing apparatus that is shown diagrammatically in Fig, l;

Figs. 6 and '7 are end and plan views, respectively, oi the apparatus, the hinged lid being omitted from F1316; v

Fig. 8 is a plan view of a testing unit that includes the circuit elements shown in 4the Fig. 2 diagram; and v Fig. 9 is a side elevation of the same, with parts broken awayv to show a portion of the rectier assembly.

As is .indicated by the descriptions of Figs. 1 and 2, both forms of the invention are designed lto supply a direct current to the Joint or switch contacts under test. This is essential since the inductivereactance component of the' circuit im- 3 c y l assegna pedance drops to zero when a direct current is employed, thus making -it possible to read accurately the resistance ratio of the instrument and the test circuits. Furthermore, the direct cur- 5 rent must be relatively high to avoid false indications of the contact resistance in the case of circuit breakers that have operated a number of times to interrupt heavy short circuits. Such contacts, although so badly eroded as to have a high contact resistance at a normal load current oi' high magnitude, may have point contacts in good engagement that present a low or normal resistance to a low test current. A test current of the order of 100 amperes or more will melt down small point contacts and thus est-acusa e contact resistance identical with or approximatina that which ernste when the joint or switch contacts are in service and carrying load currents substantially higher than a 100 to 200 ampere test w current.

En Fia. l, the brolscn line rectangle i indicates a bon creasing that houses the instruments, switches. etc., and has terminals for connection to the current source andto a cable that extends tc the test specimen. 'The input terminals 2, 3 are to be connected to a direct current source of hiel: current capacity auch as, for example, the storage batteries usually provided at stations and n su'ostatlons 'for operating circuit breakers and e@ other protective equipment. Terminal 2 is connected through an ammeter t and its instrument shunt il to the xed contact oi' a magnetic switch il; the moving contact being connected through lead t, al current-limiting resistor il and lead il @il to an output terminal it. The other output terminal ilis directly connected to the input terminal 3 by a strap i2; and the solenoid it oi the magnetic switch is connected. in series with a push-button switch it, between the opposite dil sides of the direct current line.

The ammeter il isa small milliammeter for measuring the total current new through the test unit, the milliammeter and its shunt resistance l5 losing so designed that the full scale reading ci the instrument corresponds to', i'or example, -lilil amperes throuah the testing apparatus. A similar milliammeter it is mounted on the casina t for measuring that portion oi Vthe total test current which flows through a shunt that is cond@ nested, as will be described later, across the joints or switch contacts under test. The am.. meter It is connected by leads it to instrument terminals il' that entend through o. wall ci the casing l.

55 The casing l may be placed at a point near the equipment to be tested, and connections are made to the test specimen through heavyiiexible conductors It and smaller ilexible conductors It that are bound at intervals by tape or cord 2li do to form a cable ci desired length, `for example about 50 feet. The inner ends oi conductors IB have lugs. not shown, .for connection to the current output terminals ld, Il,l respectively, and the corresponding ends of the conductors I! have o5 lugs lor engagement with-the instrument'ter- `minals il. The outer ends of the instrument leads or conductors' It are connected to the respective current conductors-4I, and the leads are twisted throughout the greater part of the 70 length of the cable to prevent a pick-up from stray magnetic fields produced by adjacent current carrying conductors. The shunt resistance 2l that is connected across the leads i! adjacent their outer ends is preferably the range-adjust- 75 ina shunt for the instrument Il when the value oi' that resistance is ci! the same order as the maximum allowable resistance oi the iolnta or contacts to be tested but an additional loading resistor may be connected in series with the instrument shunt 2| when the instrument i5 is of 5 such design that its full scale deflection is obtained with an instrument shunt resistance that is substantially lower' than the normal re siatances of the joints or contacts to he tested.

As shown in Fig. 1, the test unit is connected 10 through the cable I8, IB to an oil circuit breaker comprising a ypair oi main contacts 22 and arcing contacts 23 that are normally connected by a Jumper bar Il, the bar 2| being moved downwardly by a rod 2l and mechanism, not shown, 15

to open the circuit for normal switching operations or upon predetermined overload conditions. It is to be understood that the illustration oi the circuit breaker is diagrammatic and that the particular design of the equipment that may be 20 tested is not a feature of this invention.

The test unit for use with an alternating cur rent source, as shown in Fig. 2, comprises a cac ing di having input terminals d2, 3S for connection to theusual 110 volt, titll cycles power linev 25 and a step-down transformer 3d, the primary ci. the transformer being connected across the terminals through. a push-'button switch 35 and an adjusting resistance 3d. The transformer secondary is connected to one set of terminals of a copper oxide type of full wave rectier 8l, and the other set of terminals 2', 3 delivers a direct current oi the order of 200 amper-es to the cutput terminals itl, li. A choke 33 for smoothinl; out the rectiiled current is connected, in 35 series with the shunt 5 ol nmmeter d, between the bridge terminal 2' and output terminal It. and the bridge terminal 3 is connected to output terminal ii by a. lead i2'. Thev ammeter it is connected through leads IB to the instrument terminals. The cable as shown in Fig. l may ce used with the test unit of Flu. 2.

The method oi testing the conductivity ci the contacta of an oil circuit breaker is asl-follows.

The breaker la removed from service in the usual it manner by connecting the load to another section oi the distribution system and the cable lleads Ill are connected to the breaker terminals in place oi' the normal circuit connections. The

test vunit of Fic. 1 is used where direct current 50 A is available, the current source being connected to the input terminals 2. 8. The test circuit is completed hyV depressing push button td to energize. the solenoid I3 oi the magnetic switch, and the readings o! the instruments t and i6 55 are recorded.

The total current ow is registered by instrument t and the current through the shunt resistance 2l is registered on instrument lo. These "vlues are read both for the normal closed position of the breaker and for the partially open position in which the jumped 24 has lett the main contacts 22 and engages only the arclng contacts It. The resistance of the circuit breaker, from one outer terminal to the other. may be computed from the two current values and the known value of the resistance 2l that is :hunted across the breaker but, for speed and convenience in the field, it is preferable to Judge the condition of circuit breakers by referrinz to measured currentvalues to previously prepared curve sheets auch as shown in Figs. 3 and 4. Each of the curves o! Fig. 3 indicates, for a particular type ot circultbreaker, the maximum current ilow in 'l5 the shunt resistance 2|."for different values of total current now, that corresponds to a satisfactory condition of the contacts'andl other'electrlcal joints of that circuit breaker. Each of the 3 curves was obtained by checking the conductivity measurementson a large number of circuit breakers of a given type by inspections of the contacts and any bolted connections between the outer terminals and the contacts.

Curve A wasl plotted from tests lon a particular type of |32 and |154 kilovolt circuit breaker,

curves-B andB were plotted for the main and arclng contacts of another type of breaker, and

curve C was plottedfor the main contacts of-a l5 3000 ampere circuit breaker. All of the curves are -based upon the same value, specically 0.0019l ohm. for the resistance 2| that is shunted across- The wide variation in thev maximum shunt current reading that corre- .20 sponds to a satisfactory condition of breakers oi the circuit breaker.

different' types, or Ofdi'erent contacts of a breaker of a given type, is explained by diierences in the length and the cross-section of the conducting path through the circuit breakers.

Further inspection is of course necessary whenl the measured value of the current Ilow through the shunt resistance 2l is greater than the maximum allowance indicated by the Fig. 3 -curve for that .type of breaker. Various causes for an unduly high resistance have been found during-the use oi this testing apparatus and, in many instances, the particular defects that were responsible` for the high resistance would not have been located by the prior method of visual inspection.

' 35 The most common causes of-high resistanceare burnt, pitted or defectivel circuit-breaker vcontacts resulting from the breaker opening under heavy overloads or from loose connections, but it has been found that poorly assembled terminal bushings are also responsible for .some high resistance joints. i l

'I'he total current flow may be set to exactly 200 amperes or any other selected value when the resistance 36 in the transformer primary circuit. It is not convenient to adjust the main line current to a particular value when the Fig. V1 circuit is hsed, but adjustment to a particular value is not essential as the Fig. 3 curve sheet shows permissible-maximum values oi' shunt current for a widerange of total current values.

'Ihe curve D of Fig. 4 shows the relation between the resistance of the circuit breaker and current fiow in the shunt resistance for a particular value of the shunt resistance and a predetermined total current flow. These predetermined values for curve D were a shunt resistance of' 0.0019 ohm and a total current of 200 amperes.

` 00 The curves joi Fig. 3 were plotted for the same shunt resistance and therefore the maximum allowable resistance of the circuit breakers c an be determined from the curve sheets. The magmtude of the resistance values to be measured is 05 indicated by curve D which shows that the maximum allowable resistancefcrthe |32 and |54 'kilovolt circuit breakers, curve A of Fig. 3, is about '.001 ohm. The maximum allowable resistance for other types 'of circuit breakers is'substantially lower and, in general,l the measured resistances will be far below the maximum allowable Avalues indicated by the curves oi Eig. 3.

The instruments 4 and I5 are preferably identical and have identical range-adjusting shunts 5 and 2|', respectively, thus eliminating-the possi- -both instruments errors of the same magnitude. 'I'he conditionof 10 bility of overloading the instruments during tests and facilitating pe odic tests of the condition of the instrumentsl and cable connections. vA fair test of the condition of the instruments may be had at'the start of each test by noting that the 5 1 instruments 4 and l5 indicate the same current flow before the conductors I8 are connected to the test specimen since itis not probable thatv will simultaneously develop Vthe cable connections and the accuracy of the instrument I5 may be checked from time to time by connecting a known resistance and a check ammeter between the outer ends of conductors I8. 'Ihe check ammeter and instrument i5 l5 should indicatethe same current value when. as

is preferable, the known resistancehas the 'same value as resistance 2l. After checking the instrument I6, the instrument 6 may be checked by removing the known resistance, thus estab- 20- lishing the same current flow through the instrument shunts E and 2|.

'I'he conductivity testing apparatus of Fig. i. may be assembled in a small portable unit -such ,as shown in Figs.v 5, 6 and '7. The top wall 40 of 25 the casing 'l may be a panel of woo or other" insulating material on which the ammeters 4 and 1E, and the push button switch are mounted, and

. the side walls may beperforated plates 4| thatl are attached to the metalframe 42 oi' the box. 30l

The perforated plates aiord adequate lair cooling for the current-limiting resistor 8 that is supported from the top wall 40 by brackets 43. .All

1 of the terminals are mounted on one end wall of a the box. and the instruments are mounted on the 35 top wall at the end above the terminals. The leads from instrument 4 to its shunt 5 are preferably'quite long for convenience of -assembly and the extra length of the leads is heldin xed position with respect to the other circuit elements 40 instruments is hinged to one end of the box, and i -a leather carrying s trap 48 has slotted ends for A attachment to headed studs 61 on the opposite 45- ends of the box.

A physical embodiment of the Fig. 2 testing- '.circuit, as shown in Figs. 8 and l9, comprises a.

metal casing 3|' that houses all of the circuitelements, has 'parts of hinges 49 at its upper edge 50 for the' attachment of a cover 50, and is provided with a carrying strap 5|. The rectier bridge .consists of a large number of copper oxide rectiiier assemblies 31 of conventional design that are mounted on angle bars 52 by bolts 53. The 55 rectiiier assemblies are close to the walls ofthe casing 3l', and the transformer 36 and reactor 38 are centrally located within the casing. The transformer 34' is arranged above the reactor to y shield the instruments 4 and l5 from the reactor, .60

and a sheet 54 of insulating material is placed between these elements. The input terminals 32, 33 may conveniently take the form of a Hubbell" socket on the vtop wall of the casing 3|', and the terminals i0', ii' and l1 of the power and in- 68 strument circuits, respectively. may be mounted on a strip 55 of insulating material that is' secured tothe top wail. The push-button switch is and the knob' ior adjusting the resistance 38 are arranged at opposite sides of the instru- 70 xments d and i5. l

The described constructions are practical and convenient-for neld use but it is obvious that other arrangements of' the essential elements oi' the conductivity testing circuits may be used. 7l

Ammeters of the type that carry the entire curvlew of the rent now couldbe employed but, in heavy current, it is less expensive and more convenient to employ smallmilliammeters with resistance shunts.

I claim:

l. Apparatus for measuring the conductivity of normally low resistance electrical connections that carry heavy currents in an electrical distribution system, said apparatus comprising input terminals for connection to a current source, output terminals connectedto said input terminals through a normally open switch and a current-measuring instrument, exible conductors for connecting said output terminals to the electrical connection to be tested, a resistance connected between the ends of said conductors that are to be connected to the electrical connection to be tested, an instrument :lor measuring the current dow through said resistance, and instrument leads connecting said second instrument to said resistance.

2. A portable apparatus for measuring the conductivity of normally low resistance electrical elements in an electrical distribution system, said apparatus comprising a casing, a pair of current measuring instruments carried by said casing, input terminals on said casing for connection to a current source, output terminals on said casing, flexible conductors for connecting said output terminalsv to the electrical element to be tested, connections between said input and output terminals including circuit elements connected to one of said instruments to condition the same to register the total current tlow from said current source, a resistance connected between said conductors and thereby shunted across trical element to be tested, and connecting the second instrument to said resistance to condition that instrument to register the current flow through said resistance.

3. A portable apparatus as claimed wherein said resistance is connected betweensaid conductors adjacent the ends thereof that are to be connected to the electrical element to be tested.

4. A portable apparatus as claimed in claim 2, wherein said resistance is connected between said conductors adjacent the ends thereof that are to be connected to the electrical element to be tested. and said instrument leads are twisted upon each other and secured ductors to form a cable. v l

5. In. a portable apparatus for measuring the conductivity of normally low resistance elements in an electrical distribution system, the combinaor high current capacity, output instrument through said apparatus, instrument terminale on to said exible conand output said easing and connected to the second muusmmeter, of a cable comprising conductors for connecting said output terminals to the electrical element to be tested, a resistance connected be-` tween the ends or said conductors that are Ato be connected to the electrical element. and instrument leads extending from said instrument terminals to said second resistance to condition the second miliiammeter to indicate the current now through said second resistance, whereby the conductivity of the electrical element may be determined from a comparison oi the readings of the two milliammeters. v

6. In a portable apparatus, the invention as claimed in claim 5, wherein said second resistance is a range-adJusting shunt which conditions said second milliammeter for measurements in the same current range as that of the nrst milliammeter.

7. ln. apparatus i'or measuring the conductivity of an electrical element of a distribution system, a casing carrying a pair oi current measuring instruments, input terminals on said casing for connection to an alternating current source, a transformer having a primary winding for connection between said input terminals and a secondary winding, rectifier means connected across said secondary winding and having terminals across which a direct current oi a high order is developed, output terminals on said casing, circuit elements connecting said rectiiier means tervments including means for connecting one of said currents measuring instruments in circuit to indicate the total current output of said rectifier means, conductors for connecting said output terminals to the electrical element to be tested. a resistance connected between the ends of said conductors that are to be connected to the electrical element, and means comprising said second current measuring instrument and leads connecting the same to said resistance for indicating the current now through said resistance. whereby the conductivity o! the electrical element may be determined from a comparison oi the readings of said instruments.

8. In apparatus for measuring conductivity, the invention as claimed in claim '1. in combination with means in circuity with the primary winding o! said transformer for adjusting the total current now through said apparatus to a predetermined value.

9. The method of determining the conductivity o! an o il circuit breaker which comprises shunting the circuit breaker by a resistance oi the order o! the normal resistance o! the circuit breaker. passing through said circuit breaker and shunt resistance a direct current-of theorder of upward of amperes, measuring the total current ilow and the current flow through said shunt resistance, 'and determining the conductivity of the circuit breaker by a comparison of the two measured current values.

GEORGE A. MATTHEWS'.` 

